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My AE86 Build


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I pulled this car from the junkyard in 2004. It was comlete at the time and I couldn't imagine it being left in the yard just waiting to be crushed. I bought it the day after it was put in the yard. The only problem was a bent tie rod on the passenger side. I had roughly 145,XXX miles on it when it was salvaged.

 

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Here are some I took today. I just got it to the point where I can put the front tires on the ground and reclaim two jack stands. It still doesn't have a set of tension rods or front sway bar yet. Next goal is to put the rear diff back together and put some rear tires on. Then I can put the car on wheel dollys and get some other work done on it.

 

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Here are some updated photos. My dad had a brand new looking CA18DE laying in wait in his garage. He bought it almost 6 years ago and we've been eager to see how it runs so I decided to try and swap it into the junkyard car for now. Here are some photos of the misc parts I now have. I'll get pics of the trans and engine once they're in the garage.

 

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In the wiring box is a complete Pulsar 1.8L DE chassis harness, a DE Engine harness, a CA16DE engine harness and a cut section of a CA16DE chassis harness. The two ECUs are both DEs, one US DE from an 88 Pulsar and one Canadian DE from an 88 Pulsar. I should have the engine on a stand sometime this week, and the transmission is up in the air at the moment.

 

Here are some photos of the spare CA head I have. My dad traded a spare ignitor for the head...he ended up getting a complete head, cam gears, RWD intake manifold (with throttle body, injectors, fuel rail, etc.). Not bad. Still clearing space in the garage to bring the engine home. I need to make room for another engine stand.

 

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It looks fairly unused. When my dad got it back to his garage it still had a brand new factory oil filter on it, the oil that was still in the engine was extremely clean, the cams had no wear marks, the timing belt and all of the seals were brand new, all of the sensors were as near to new as the get, and the O2 sensor showed very little signs of use. It's literally as if the owner drove the car off of the lot and destroyed the car it was in. We're still looking for the flywheel and clutch...it's somewhere in his garage amidst a mountain of SVX and turbo Grand Am parts and pieces.

 

I've had these for a couple months. I just forgot to take photos. I bought them from a dealer online for 110 shipped. Not too bad. Cibie E-Code H4 housings, brand new, with some free halogen H4 bulbs.

 

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New parts to install. I'm hoping to have these on this weekend. Should be an easy enough swap from one setup to this. I'll get the steering recentered and the initial tie-rod adjustment done, install the new steering knuckles on the second adjustment point, adjust the tension rods and install them on the new control arms, and get everything bolted down. I'll take some comparison photos of the before and after steering angle once I get to things.

 

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The only other thing that should get accomplished this weekend is grinding all the brackets off of the 8.8 rear diff so I can take to to Alamo Performance on Monday to get it narrowed and the new housing ends welded on. I'll take some photos of the work this weekend.

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Rondell Bars: 12 Fronts 7 Rears All Shipped Last Thursday

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Here are the mocked up flanges for the engine mount brackets. I'm still working on the widths, but everything seems like it will bolt up just fine. I won't be using the round bar triangulate mounts. I'm going to use mounts similar to the stock driverside AE86 mount.

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I've been busy and haven't had too much time to work on the car...not to mention I've been dealing with various maintenance issues with the 240. I ended up purchasing some reman'd calipers and mounted them up. No I just need to get some rotors, brake pads, and reroute the brake lines (with either hard lines or braided).

 

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I also popped the pan off of the CA. I wanted to reseal the pan, but also wanted to check the condition of things in the case. Turns out everything looks new. I really do think the Bluebird this engine was installed in either was in a wreck very early in the cars life, or the engine was replaced and the car was soon junked. All the sensors, accessory equipment, etc are all practically new.

 

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Finally got the CA in. The transmission is touching the underbody, so I'm going to need some .5"-1" subframe spacers so I can Make some room. I'll need them to drop the engine down too, b/c the cam gear cover protrudes above the fender line about .5-1".

 

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The shifter will move back about 3-4 inches. Something that I'll personally appreciate. If I ever want it in the stock position I can source a RB25 trans and it will fit like stock. Since this was just a mock up install I'll remove it once I get the engine and trans mounts done. I think I'm going to cut the radiator support and make it removable b/c putting the engine in the way it is was a lot more irritating than in needed to be.

 

Right now everything is supported by the transmission. I have two jack stands under the flat sections of the transmission which guides the engine into its natural tilt.

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